GM 17095069 Manifold Assembly, Upper Intake (W/ Throttle Body)

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First off, disconnect the negative battery cable. For 1994 and 1995 VIN Z models, take out the upper fan shroud, air cleaner assembly, drain the cooling system, and disconnect the radiator as well as heater hoses. Also disassemble the spark plug wires, coil and distributor by unbolting emission relays bracket and remove rear braces from drive belt tensioner, remembering to mark relationship of distributor rotor with respect to other parts before removal. Disconnect the fuel lines at TBI unit; remove accelerator cables, cruise control cables, TV cables from manifold; detach vacuum brake booster pipe; label manifold lines & wires and remove them. Move up EGR hose whilst loosening manifold mounting bolts. Prying front of manifold loose after removing all bolts for that purpose is now allowed. In case of 1996 or later models you will need to start from taking out upper fan shroud then move on to air cleaner assembly followed by draining cooling system plus disconnecting upper hoses from radiator as well as heater. Next unbolt EGR valve and take off ignition coil carefully. Remove small brace between intake manifold & AC compressor then turn engine to TDC for number one piston-prior to removing distributor. Old gasket material must be removed to guarantee clean mating surfaces during re-installation; apply RTV sealant if necessary. Be sure new gaskets are properly aligned when putting in place new intake manifold while sealant is still wet on it. Proceed accordingly tightening recommended sequence's bolts once more when finished reverse remaining steps beginning with starting engine thereafter checking for leaks.

Follow similar steps starting from removing the upper fan shroud, air cleaner assembly, draining the cooling system, and disconnecting the upper radiator and heater hoses. Unbolt the EGR valve, move heater hoses, and remove the ignition coil. Remove the small brace from the air conditioning compressor to the intake manifold and turn the engine to TDC for number 1 piston before removing the distributor.

Before accessing the intake manifold, you need to remove the air intake duct assembly, the PCV valve, hose connecting the intake manifold to the valve cover, and, in 1997 and earlier MFI models, the upper intake manifold.

Before installing the manifold, you should clean the cylinder head and manifold gasket surfaces and apply a thin coat of RTV sealant to the intake manifold and cylinder head mating surfaces.

You should remove the spark plug wires from the coil pack, mark them for reassembly, and pull them up through the intake manifold, laying them over the left side of the engine.

Remove the two rear braces from the drive belt tensioner, unbolt the emission relays bracket, and proceed to remove the spark plug wires, coil, and distributor, marking the distributor rotor's relationship before removal. Disconnect the fuel lines at the TBI unit, remove accelerator, cruise control, and TV cables from the manifold, detach the vacuum brake booster pipe, and label and disconnect various lines and wires at the manifold and TBI unit. Move the EGR hose and begin loosening the manifold mounting bolts, followed by prying up the front of the manifold after removing all bolts.

Remove the two rear braces from the drive belt tensioner, unbolt the emission relays bracket, and proceed to remove the spark plug wires, coil, and distributor, marking the distributor rotor's relationship before removal. Disconnect the fuel lines at the TBI unit, remove accelerator, cruise control, and TV cables from the manifold, detach the vacuum brake booster pipe, and label and disconnect various lines and wires at the manifold and TBI unit. Move the EGR hose and begin loosening the manifold mounting bolts, followed by prying up the front of the manifold after removing all bolts.

Before separating the manifold from the cylinder head, you should remove the bolt holding the heater hose tube to the right rear of the manifold.